Non-stick paint tray

ABSTRACT

A paint tray, for use in painting with a paint roller and/or paint brush having a non-stick coating applied thereto to improve the cleanability thereof.

FIELD OF THE INVENTION

Conventional paint trays, for use with rollers in applying paint to wallsurfaces and the like, may be made of any suitable material, such asmetal or plastic and are generally roughly rectangular in shape. Thetray typically has a depression or well near one end into which thepainter pours a supply of paint. The well generally terminates in aninclined surface upon which the painter may roll the paint roller toremove excess paint therefrom.

During periods of non-use of the roller, the painter conventionallyplaces the roller upon the tray with the paint applying portion restingon the inclined surface. Sometimes the paint tray is left out for a longperiod of time before it is cleaned, resulting in the paint drying andsticking to the tray. Needless to say, washing/cleaning up from such apainting project can be a time consuming and tedious task.

Given the circumstances described above the users of these paint trayssometimes throw out the paint tray rather than attending to the stepsnecessary to fully clean the tray. Even when it is not thrown out, thepaint tray may not be cleaned as fully as desired resulting incontamination to the paint used in the next paint job. For thesereasons, it can be seen that it would be desirable to have a solution oran improvement on the prior art that addresses this problem.

One well-known prior art “solution” to this problem is the use of athrow away plastic tray liner which is not as expensive, bulky or heavyas the underlying tray. However, such liners can create undesirablerefuse. Furthermore, the liners sometimes are not held in place in thetrays securely, thereby causing potential problems with spillage, etc.Needless to say, this is not an ideal situation. Other prior artsolutions suggest the use of a smooth and/or non-stick surface for thesurface of the paint tray, but do not disclose operative ways ofincorporating such surfaces, particularly surfaces including afluoropolymer-type non-stick coating, into a paint tray.

SUMMARY OF THE INVENTION

The invention herein relates to a paint tray for use for dispensingpaint to a roller and/or brush for application to a surface beingpainted which may be simply and easily cleaned for reuse, which aids inthe picking up of the paint from the tray as well as which allows morepaint to be removed from the tray resulting in less waste and less paintthat ultimately needs to be cleaned up. In particular, the presentinvention comprises a paint tray having an inclined surface, a well, andside walls for holding paint in the tray that are coated with anon-stick coating, and in particular, a fluoropolymer-type non-stickcoating. Non-limiting examples of non-stick fluoropolymer resins orinorganic dry lubricants in accordance with the present inventioninclude but are not limited to solutions comprisingpolytetrafluoroethylene (PTFE), fluorinated ethylenepropylene (FEP),polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), ethylenechlorotrifluoroethylene (ECTFE); molybdenum disulfide (MoS2), and blendsthereof. Many of these coatings are available commercially under theTeflon® trademark. The non-stick solutions can further compriseconventionally known film-formers to produce composite non-stickcoatings of superior performance. These coatings may be applied toconventional stamped metal paint trays, made of aluminum or steel, as isknown in the art. The coating may be applied via spraying, dipping orany other method as is known to those of ordinary skill in the art.Preferably the coating is baked on the tray in order to improve theadhesion thereof.

Additionally within the scope of the invention is the use of a plasticfor the tray substrate having a non-stick material, such as afluoropolymer, impregnated therein. The plastic may be injection molded,thermoformed, vacuumformed, or formed in any other method known in theart into the desired paint tray shape. Additionally, plastics could beused that have the non-stick coating applied to the plastic after theplastic is formed into the desired paint tray shape. Also within thescope of the invention is the use of a plastic or metal sheet having anon-stick coating, such as a fluoropolymer, applied to a sheet prior tostamping the sheet into the desired paint tray shape.

These and other objects will become apparent from the foregoing andongoing specification, the drawings, and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings, wherein like reference numerals identify correspondingparts:

FIG. 1 is a perspective illustration of a paint tray and a paint rolleraccording to the principles of the present invention;

FIG. 2 is a side elevation of the paint tray of FIG. 1;

FIG. 3 is a perspective illustration of a leg attached to an undersideof a paint tray using a method in accordance with the present invention;

FIG. 4 is a perspective illustration of the attachment portion of a legas seen from the top side of a paint tray in accordance with the presentinvention; and

FIG. 5 is a perspective illustration of paint being removed from a painttray in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 illustrate a conventional paint tray 10 in accordance withthe present invention having a top surface 11, a bottom surface 13, afront edge or surface 12 and a rear edge or surface 14, which may besubstantially coplanar, having side walls 16, 18. The tray includes awell portion 20 positioned adjacent to and below the rear surface 14 forthe storage of paint or the like and an inclined surface 22 taperingupward from the paint well 20 to the front surface 12.

The paint tray 10 may include a peripheral outwardly extending, lateralflange 24. The tray 10 may include a pair of legs 26, 28 extendingupwardly inside the shallow end of the tray 10. Both legs 26, 28 may beconstructed to be identical for simplicity and ease of manufacture ifdesired. Each leg 26, 28 may include an upper pin or plug portion 30, 32for keeping the legs 26, 28 in the tray 10 and may include feet 34, 36to help keep the tray 10 standing upright or to latch onto a paintholder tray on a ladder. The inclined portion 22 of the tray 10preferably includes protrusions 38 to help distribute paint on theroller cover 40 of the roller 42. Additionally, the non-stick coatingmay be applied to: all of the components of the tray 10; only thecomponents that are designed to contact the paint such as the front edge12, rear edge 14, side walls 16, 18, well 20, and inclined surface 22;only the top surface 11 of the tray 10; or any combination of thesecomponents.

Of course, the invention contemplates that various modifications andchanges may be made to the construction of the tray 10. For example, thelegs 26, 28 may be stamped or heat-staked to the bottom of the tray 10,or the tray 10 may be formed in a manner where such legs are unnecessaryaltogether. One embodiment contemplated by the invention, as shown morefully in FIGS. 3 and 4, includes attaching the legs 26, 28 to the bottomsurface 13 of the paint tray 10 by “toggling” (or pressing) the legs 26,28 mechanically thereto. This method is particularly advantageous whenthe legs 26, 28 are added after the non-stick coating has been appliedto the paint tray 10. This is because the toggling method does notrequire the use of heat or flame that are required by the heat stakingor welding methods that might damage the non-stick coating.Additionally, as opposed to using legs that protrude through the topsurface 11 of the tray 10 (as shown in FIGS. 1 and 2), the togglingmethod does not require that a hole or slot be cut in the top surface 11of the tray 10, thereby preventing damage of the non-stick coating.Using the toggling method, the legs 26, 28 are provided with protrusions50 thereon. The legs 26, 28 are then mechanically pressed into thebottom surface 13 of the tray 10 creating a mechanical bond between thelegs 26, 28 and the bottom surface 13 of the tray 10.

As mentioned above, any non-stick coating as known in the art may beused and are considered operative in connection with the presentinvention. In particular, fluoropolymer-type coatings are consideredoperative and within the scope of the present invention. Non-limitingexamples of these materials include polytetrafluoroethylene (PTFE),fluorinated ethylenepropylene (FEP), polyvinylidene fluoride (PVDF),perfluoroalkoxy (PFA), ethylene chlorotrifluoroethylene (ECTFE),molybdenum disulfide (MoS2), and blends thereof including organic andinorganic binders that may be added thereto. Specifically, it has beenfound that the fluoropolymer coating available from Dupont under thetradename Teflon® has been operable and may be used in accordance withthe present invention. More specifically, it has been found that theTeflon® Xtra 2 Coat Coil System for Bakeware (Primer—420-15501, Topcoat420-15803) has been operable and effective in accordance with theinvention. In that system, a two part system is used including a primerproduct that is first applied to the substrate which is followed by theapplication of the non-stick coating itself. With respect to the painttray material, any suitable material may be used. Non-limiting examplesof operable materials include plastics, tin free steel, stainless steel,aluminum, etc.

It has been found that the use of such coatings as described herein hasmade clean up of a paint tray 10 coated therewith much easier. Ease ofclean-up testing has shown that paint trays 10 coated in a non-stickcoating in accordance with the present invention outperform non-coatedtrays, particularly when the paint being used is a latex paint. In somecases, it has been unnecessary to use any water or other solvent toclean the tray if the paint is allowed to dry completely. As best shownin FIG. 5, in these conditions, the paint 52 may be easily and simply“peeled” right out of the tray 10. This is in stark contrast to priorart, non-coated trays, where the paint 52 needed to be scraped out ofthe tray (generally with minimal success). Testing has also shown thatthe non-stick coatings applied in accordance with the invention have notbeen degraded significantly by clean-up procedures using solvents,including water and/or mineral spirits, in the instances when suchsolvents are necessary and/or desirable.

Non-limiting examples of operative methods for preparing a substrate forapplication of a non-stick coating thereto for use as a paint tray 10 inaccordance with the present invention are as follows. Preferably thesubstrate (metal or plastic) to be coated is cleaned using normalindustrial practices as is known in the art, such as chemical washes orsolvent cleaning and degreasing. After cleaning, the substrate to becoated and used to form the paint tray 10 in accordance with theinvention is preferably handled with gloves to prevent fingerprintcontamination of the substrate. Preferably, the substrate is preheatedto the baking temperature to remove traces of oil and othercontaminants, especially when the substrate is porous. In a preferredembodiment, the substrate may be grit blasted to improve adhesion of thecoating. Wheel sanding, wire brushing, sanding, directional grinding andchemical etching may also be used.

The following application procedures can be used to apply the non-stickcoatings discussed herein in accordance with the present invention. Ofcourse, other application methods as conventionally known in the artalso would be operable and are considered within the scope of theinvention as well. In particular, standard industrial compressed airspray equipment may be used to spray the non-stick coating on thesubstrate. Suction, gravity or pressure type spray equipment are alsoconsidered operable. Preferably, distance from the gun to the substrateis between approximately 2-14 inches. If the gun is too close, thefinish may look rippled and if it is too far, the spray may look dry andrough.

Electrostatic guns or discs are suitable for the application ofnon-stick coatings in accordance with the invention. The advantages ofelectrostatic application include better film uniformity and potentialsavings in material, due to the reduction in overspray. Airless sprayand powder coating techniques may also be used in the manner as is knownto those of ordinary skill in the art. Furthermore, dip and flow coatingtechniques, roller coating techniques, and even brush techniques may beuseful in certain situations. Depending on the thickness of the coatingto be applied, it may be desired to apply multiple coats of thenon-stick coating

In a preferred embodiment, the non-stick coating is heat cured toachieve a strong bond with the substrate. Reaching and maintainingproper cure temperatures for a sufficient period of time to sinter, meltflow or set the film helps insure the best coating. For coatings whichare primarily PTFE, PFA and FEP fluoropolymers, no film formation maytake place below certain minimum temperatures and thus it is importantto maintain proper bake times and temperatures in order to get thedesired coating performance. For non-stick coatings which containorganic binders in addition to the fluoropolymer resins, there usuallyis a greater range of possible cure temperatures and times in order toachieve a desired film property. Still, excessive bake times and/ortemperatures may degrade the binder, causing discoloration, filmembrittlement and/or loss of adhesion.

Any commonly used type of industrial oven, batch or conveyor, may beused for curing fluoropolymer non-stick coatings in accordance with thepresent invention. This is because fluoropolymer coatings are rarelyaffected by the combustion products of coal or natural gas. Infrared andconvection ovens may also be used effectively. Factors which may affecttotal bake time include the following: residence time in the oven; heatcapacity of the oven; mass and thermal conductivity of the substrate;air circulation; oven air temperature; percent of substrate covered bythe non-stick coating; load of work in the oven; weight to surface arearatio, etc.

Following coating, the substrate may be cut into sheets of desired sizeand shape for pressing into the desired paint tray 10 form. If desired,the edges are preferably curled over to provide added strength andremove any sharp edges.

Following from the above description and invention summaries, it shouldbe apparent to those of ordinary skill in the art that, while themethods and apparatuses herein described constitute exemplaryembodiments of the present invention, the invention contained herein isnot limited to this precise embodiment and that changes may be made tosuch embodiments without departing from the scope of the invention asdefined by the claims. Additionally, it is to be understood that theinvention is defined by the claims and it is not intended that anylimitations or elements describing the exemplary embodiments set forthherein are to be incorporated into the interpretation of any claimelement unless such limitation or element is explicitly stated.Likewise, it is to be understood that it is not necessary to meet any orall of the identified advantages or objects of the invention disclosedherein in order to fall within the scope of any claims, since theinvention is defined by the claims and since inherent and/or unforeseenadvantages of the present invention may exist even though they may nothave been explicitly discussed herein.

1. A paint tray comprising: a top surface, a bottom surface, a frontedge, a rear edge, and a well shaped to receive a paint roller; anon-stick coating applied to said top surface.
 2. The paint tray ofclaim 1 further comprising an inclined portion having protrusionsthereon.
 3. The paint tray of claim 2 further comprising at least oneleg attached to said paint tray.
 4. The paint tray of claim 3 whereinsaid at least one leg is toggled to the bottom surface of said painttray.
 5. The paint tray of claim 3 wherein said at least one leg isattached through said top surface and are held in place via a pin orplug.
 6. The paint tray of claim 1 wherein said non-stick coatingincludes polytetrafluoroethylene (PTFE) or fluorinated ethylenepropylene(FEP) or polyvinylidene fluoride (PVDF) or perfluoroalkoxy (PFA) orethylene chlorotrifluoroethylene (ECTFE) or molybdenum disulfide (MoS2).7. The paint tray of claim 1 further comprising side walls, said sidewalls terminating in a lateral flange.
 8. The paint tray of claim 7wherein said lateral flange is curled.
 9. The paint tray of claim 1wherein said paint tray is generally rectangular in shape.
 10. The painttray of claim 1 wherein said paint tray is fabricated from a metal. 11.The paint tray of claim 1 wherein said paint tray is fabricated from aplastic.
 12. A paint tray comprising: a top surface, a bottom surface, afront edge, a rear edge, side walls, an inclined portion and a wellshaped to receive a paint roller; said inclined portion includingprotrusions thereon; a fluoropolymer non-stick coating applied to saidtop surface.
 13. The paint tray of claim 12 further comprising at leastone leg attached to said paint tray.
 14. The paint tray of claim 13wherein said at least one leg is toggled to the bottom surface of saidpaint tray.
 15. The paint tray of claim 13 wherein said at least one legis attached through said top surface and are held in place via a pin orplug.
 16. The paint tray of claim 1 wherein said non-stick coatingincludes polytetrafluoroethylene (PTFE) or fluorinated ethylenepropylene(FEP) or polyvinylidene fluoride (PVDF) or perfluoroalkoxy (PFA) orethylene chlorotrifluoroethylene (ECTFE) or molybdenum disulfide (MoS2).17. The paint tray of claim 12 wherein said side walls terminate in alateral flange.
 18. The paint tray of claim 17 wherein said lateralflange is curled.
 19. The paint tray of claim 12 wherein said paint trayis generally rectangular in shape.
 20. A paint tray comprising: a topsurface, a bottom surface, a front edge, a rear edge, at least one leg,an inclined portion and a well shaped to receive a paint roller; saidinclined portion including protrusions thereon; a fluoropolymernon-stick coating applied to said top surface.
 21. The paint tray ofclaim 20 wherein a primer is applied between said top surface and saidfluoropolymer non-stick coating.
 22. The paint tray of claim 20 whereinsaid paint tray is fabricated from aluminum or tin free steel.